US5505788A - Thermally regulated photovoltaic roofing assembly - Google Patents

Thermally regulated photovoltaic roofing assembly Download PDF

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Publication number
US5505788A
US5505788A US08/267,499 US26749994A US5505788A US 5505788 A US5505788 A US 5505788A US 26749994 A US26749994 A US 26749994A US 5505788 A US5505788 A US 5505788A
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United States
Prior art keywords
assembly
roofing
photovoltaic
photovoltaic modules
part integral
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US08/267,499
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English (en)
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Thomas L. Dinwoodie
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PLUTO ACQUISTION Co LLC
SunPower Corp
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Individual
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US case filed in Oregon District Court litigation https://portal.unifiedpatents.com/litigation/Oregon%20District%20Court/case/6%3A08-cv-00148 Source: District Court Jurisdiction: Oregon District Court "Unified Patents Litigation Data" by Unified Patents is licensed under a Creative Commons Attribution 4.0 International License.
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US case filed in California Northern District Court litigation https://portal.unifiedpatents.com/litigation/California%20Northern%20District%20Court/case/5%3A08-cv-02807 Source: District Court Jurisdiction: California Northern District Court "Unified Patents Litigation Data" by Unified Patents is licensed under a Creative Commons Attribution 4.0 International License.
US case filed in California Northern District Court litigation https://portal.unifiedpatents.com/litigation/California%20Northern%20District%20Court/case/4%3A08-cv-02807 Source: District Court Jurisdiction: California Northern District Court "Unified Patents Litigation Data" by Unified Patents is licensed under a Creative Commons Attribution 4.0 International License.
Priority to US08/267,499 priority Critical patent/US5505788A/en
Application filed by Individual filed Critical Individual
Priority to AU29153/95A priority patent/AU691635B2/en
Priority to JP50346796A priority patent/JP3777454B2/ja
Priority to MX9606581A priority patent/MX9606581A/es
Priority to CA002192838A priority patent/CA2192838C/fr
Priority to EP95924767A priority patent/EP0767859A4/fr
Priority to PCT/US1995/008321 priority patent/WO1996000827A1/fr
Priority to CN95193861A priority patent/CN1082124C/zh
Publication of US5505788A publication Critical patent/US5505788A/en
Application granted granted Critical
Assigned to POWERLIGHT CORPORATION reassignment POWERLIGHT CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DINWOODIE, THOMAS L.
Assigned to SUNPOWER CORPORATION, SYSTEMS reassignment SUNPOWER CORPORATION, SYSTEMS CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: POWERLIGHT CORPORATION
Assigned to PLUTO ACQUISTION COMPANY LLC reassignment PLUTO ACQUISTION COMPANY LLC MERGER (SEE DOCUMENT FOR DETAILS). Assignors: POWERLIGHT CORPORATION
Assigned to POWERLIGHT CORPORATION reassignment POWERLIGHT CORPORATION CONTRIBUTION AND ASSUMPTION AGREEMENT Assignors: PLUTO ACQUISTION COMPANY LLC
Assigned to SUNPOWER CORPORATION reassignment SUNPOWER CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SUNPOWER CORPORATION, SYSTEMS
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00—Supporting structures for PV modules
    • H02S20/20—Supporting structures directly fixed to an immovable object
    • H02S20/22—Supporting structures directly fixed to an immovable object specially adapted for buildings
    • H02S20/23—Supporting structures directly fixed to an immovable object specially adapted for buildings specially adapted for roof structures
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/10—Arrangement of stationary mountings or supports for solar heat collector modules extending in directions away from a supporting surface
    • F24S25/11—Arrangement of stationary mountings or supports for solar heat collector modules extending in directions away from a supporting surface using shaped bodies, e.g. concrete elements, foamed elements or moulded box-like elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/10—Arrangement of stationary mountings or supports for solar heat collector modules extending in directions away from a supporting surface
    • F24S25/15—Arrangement of stationary mountings or supports for solar heat collector modules extending in directions away from a supporting surface using bent plates; using assemblies of plates
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/10—Arrangement of stationary mountings or supports for solar heat collector modules extending in directions away from a supporting surface
    • F24S25/16—Arrangement of interconnected standing structures; Standing structures having separate supporting portions for adjacent modules
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/30—Arrangement of stationary mountings or supports for solar heat collector modules using elongate rigid mounting elements extending substantially along the supporting surface, e.g. for covering buildings with solar heat collectors
    • F24S25/33—Arrangement of stationary mountings or supports for solar heat collector modules using elongate rigid mounting elements extending substantially along the supporting surface, e.g. for covering buildings with solar heat collectors forming substantially planar assemblies, e.g. of coplanar or stacked profiles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/40—Arrangement of stationary mountings or supports for solar heat collector modules using plate-like mounting elements, e.g. profiled or corrugated plates; Plate-like module frames 
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S60/00—Arrangements for storing heat collected by solar heat collectors
    • F24S60/10—Arrangements for storing heat collected by solar heat collectors using latent heat
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/052—Cooling means directly associated or integrated with the PV cell, e.g. integrated Peltier elements for active cooling or heat sinks directly associated with the PV cells
    • H01L31/0521—Cooling means directly associated or integrated with the PV cell, e.g. integrated Peltier elements for active cooling or heat sinks directly associated with the PV cells using a gaseous or a liquid coolant, e.g. air flow ventilation, water circulation
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
    • E04D13/16—Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure
    • E04D13/1687—Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure the insulating material having provisions for roof drainage
    • E04D13/1693—Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure the insulating material having provisions for roof drainage the upper surface of the insulating material forming an inclined surface
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S2025/01—Special support components; Methods of use
    • F24S2025/02—Ballasting means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
    • F24S2025/601—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules by bonding, e.g. by using adhesives
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S40/00—Safety or protection arrangements of solar heat collectors; Preventing malfunction of solar heat collectors
    • F24S40/80—Accommodating differential expansion of solar collector elements
    • F24S40/85—Arrangements for protecting solar collectors against adverse weather conditions
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00—Integration of renewable energy sources in buildings
    • Y02B10/10—Photovoltaic [PV]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00—Integration of renewable energy sources in buildings
    • Y02B10/20—Solar thermal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/40—Solar thermal energy, e.g. solar towers
    • Y02E10/47—Mountings or tracking
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S136/00—Batteries: thermoelectric and photoelectric
    • Y10S136/291—Applications

Definitions

  • This invention generally relates to a photovoltaic roofing assembly, and in particular to a photovoltaic roofing assembly which can regulate the temperatures experienced by the solar, cells and requires no roof penetrations for hold-down to the roof surface.
  • Woodring's assembly includes a plurality of insulation blocks disposed as a layer on top of a roofing membrane, a plurality of concrete pavers disposed as a layer on top of the plurality of insulation blocks, and a plurality of photovoltaic cells, each supported on a respective paver.
  • a key feature of Woodring's assembly is the attachment of the solar cell to the supporting paver. But such attachment suffers from several disadvantages:
  • the assembly is more complicated than necessary and more costly to manufacture.
  • the assembly does not employ a method by which to limit the temperatures experienced by the solar cells and other components.
  • Solar cells are known to decline in efficiency with increasing temperatures. Hence, by offering no mechanism for temperature abatement, the assembly will operate less efficiently, with unknown long-term effects due to high temperature exposure.
  • the insulation block is inhibited from ventilating and expiring moisture.
  • the insulation block takes longer to dry out, thus reducing its insulating value and degrading the integrity of the insulation block over time.
  • the assembly has multiple modes of potential failure, which include the paver component and its means of bonding. These components will be subjected to 20-30 years of an exposed and harsh weather environment at elevated temperatures. Any form of delamination is unacceptable. Delamination would cause dislocation of solar cells due to wind loading, and potential exposure of the insulation and membrane layers below.
  • the assembly does not employ a method by which to limit the temperatures that will be experienced by the solar cells and roofing membrane, thus reducing the efficiency of the solar cells and reducing the life of the roofing membrane.
  • the assembly has multiple modes of potential failure, which include failure due to thermal stresses on the roofing membrane and its means of bonding.
  • the assembly requires roof fasteners which penetrate the protective roofing membrane, which make the installation much more complicated and more costly than is necessary. In addition, such penetrations increase the risk of water leakage, with consequent damage to the building and its contents.
  • FIG. 1 Another prior-art photovoltaic roofing assembly is shown in U.S. Pat. No. 5,316,592 issued May 31, 1994 to Dinwoodie.
  • Dinwoodie's assembly includes a plurality of insulation blocks disposed as a layer on top of a roofing membrane, and a plurality of photovoltaic cells disposed as a layer on top of the insulation block.
  • a key feature of Dinwoodie's assembly is the attachment of the solar cell to the insulation block. Such attachment suffers from a disadvantage in the use of certain photovoltaic cell materials.
  • the assembly does not employ a method by which to limit the temperatures experienced by the photovoltaic cells, and hence will operate at less efficiency than otherwise.
  • Other patents related to a photovoltaic roofing assembly include U.S. Pat. Nos.
  • an improved roofing assembly which offers the following features: a photovoltaic portion which protects the insulation and membrane layers from ultraviolet radiation and adverse weather, thus extending the life of these components; a longer-lived roofing assembly, compatible with the life of the photovoltaic portion; a roofing assembly which weighs roughly one half the cost of conventional ballasted roofs; an assembly which works with virtually all built-up and single ply membranes; an assembly which has considerable safety factor against wind uplift; and an assembly which is free of CFC's.
  • the solar module provides multiple functions as a roofing component, including ballast, weather protection, and UV protection for the insulation and waterproof membrane below, and
  • a pre-formed structure supports the photovoltaic module, while facilitating temperature regulation through heat transfer to a convecting fluid and/or phase change material.
  • a photovoltaic roofing assembly whereby, in its embodiment utilizing an insulation block as a layer between the photovoltaic module and roofing membrane, exposure of the photovoltaic modules and their respective electrical connections to moisture is minimized as a result of rainwater passing by the edges of the insulation block to the roofing membrane below, causing the entire assembly to "float" above the membrane.
  • a solar cell roofing assembly is formed with three portions.
  • One portion consists of a conventional roofing membrane installed over rooting insulation which rests on conventional roof framing.
  • a second portion consists of a plurality of photovoltaic modules, together with pre-formed spacers which enable heat exchange with a convecting fluid and/or phase change material.
  • the photovoltaic modules with pre-formed spacers have interlocking edges.
  • a third portion is a conventional rooting paver.
  • the photovoltaic module portion is situated over the roofing membrane in a manner to be exposed to solar radiation and electrically connected for transport of electricity.
  • the paver portion is situated over the same roofing membrane so is to provide walkways between aggregate areas of photovoltaic modules, and to provide perimeters around roof penetrations and equipment.
  • the photovoltaic module performs the multiple functions normally provided by a roofing paver, including ballast, UV protection, and weather protection for the membrane and insulation layers below.
  • a fan or pump unit may be added to force convection of the cooling fluid, which is preferably air, but could include other liquid or gaseous fluids. Together the three portions serve the dual function of a self-ballasted paver roofing system and a thermally regulated array of solar cells for the collection of radiant energy.
  • the solar cell roofing assembly is formed with four portions.
  • the first portion consists of a roofing membrane which rests on conventional roof framing.
  • the second portion consists of a plurality of insulation blocks.
  • the third portion consists of a plurality of photovoltaic modules, together with pre-formed spacers which enable heat exchange with a convecting fluid and/or phase change material, and which rests on the plurality of insulation blocks.
  • the insulation blocks with photovoltaic modules and pre-formed spacers have interlocking edges.
  • the photovoltaic module performs the multiple functions normally provided by a roofing paver, including ballast, UV protection, and weather protection for the membrane and insulation layers below.
  • a fourth portion of this alternate embodiment is a conventional roofing paver, located between aggregate areas of the photovoltaic modules, which provides walkways and perimeters around roof penetrations and equipment. Together the four portions serve the dual function of a protected membrane roofing system and a thermally regulated array of solar cells for the collection of radiant energy.
  • FIGS. 1a to 1d show sectional views of the invention with a flat profile and configured to enable fluid convection below the photovoltaic modules.
  • FIGS. 2a to 2c show sectional views of a second embodiment of the invention, whereby the invention shown in FIG. 1 has a tapered profile.
  • FIGS. 3a to 3c show sectional views of a third embodiment, whereby the invention has incorporates a phase change material and has a flat profile.
  • FIGS. 4a to 4c show sectional views of a fourth embodiment, whereby the invention of FIG. 3 has a tapered profile.
  • FIGS. 5a to 5c show sectional views of a fifth embodiment, whereby the invention includes an insulation block above the roofing membrane and has a flat profile.
  • FIGS. 6a to 6b show sectional views of a sixth embodiment, whereby the invention of FIG. 5 has a tapered profile.
  • FIGS. 7a to 7c show sectional views of a seventh embodiment, whereby the invention of FIG. 6 incorporates a phase change material and has a flat profile.
  • FIGS. 8a to 8c show sectional views of an eighth embodiment, whereby the invention of FIG. 7 has a tapered profile.
  • FIG. 9 shows a plan view of a building with a photovoltaic roofing assembly installed according to the invention.
  • FIGS. 1a-1d Flat Profile with Convective Layer
  • FIG. 1a shows a sectional view of a photovoltaic roofing assembly.
  • the assembly includes a plurality of photovoltaic modules 104, 106, 108, 110, a plurality of preformed spacers, pedestals, or supports 112, 114, 116, 118, 120, 122 which are respectively disposed below the plurality of photovoltaic modules 104, 106, 108, 110 and integral therewith, or fixedly connected thereto.
  • Spacers 112, 114, 116, 118, 120, 122 are disposed on top of a roofing membrane 102.
  • Membrane 102 is supported on conventional roof framing (not shown), and attached thereto by conventional methods, such as fasteners or adhesives. Membrane 102 may also rest directly on insulation block which is supported on conventional roof framing.
  • Modules 104, 106, 108, 110 are connected to conventional conductors (not shown) and are arranged in an array of modules. Each of modules 104, 106, 108, 110 has at least one photovoltaic cell.
  • photovoltaic modules include those incorporating thin-film deposition onto glass, stainless steel or ceramic substrates and manufactured by such companies as Advanced Photovoltaic Systems, Inc., Solarex Corporation, United Solar Systems Corporation, and Astropower, Inc., and modules of single or polycrystalline silicon cells such as those manufactured by Texas Instruments, Astropower, Inc., Siemens Solar Industries, and Solarex Corporation.
  • FIG. 1b shows a sectional view of an embodiment of the assembly wherein pre-formed spacers 124, 126 are disposed on top of membrane 102 and provide point support along the edges or corners for modules 104, 106, 108 to which they are fixedly connected or made integral.
  • FIG. 1b shows dimension d, representing the spacing between modules, and dimension h, representing the distance between the module and the roofing membrane.
  • the assembly has preferred dimensions whereby h measures 1/2 inch to 4 inches, depending upon the temperature to which the module and other components are to be limited.
  • the ratio of d/h preferably approaches 2 or greater in order to facilitate pressure equalization between the top and bottom side of the photovoltaic modules, thus reducing the forces of wind uplift.
  • the photovoltaic modules are preferably sized in the range of 1 ft by 1 ft to 4 ft by 8 ft, in order to be readily handled by a roofing installation crew. The size and number of the spacers are minimized in order to minimize material costs, but sufficient to provide support for the photovoltaic modules in accordance with the module material strength.
  • FIG. 1c shows a sectional view of an alternate embodiment of the assembly wherein spacers 130, 132, 134 are disposed on top of membrane 102 and provide area support for modules 104, 106, 108 to which they are fixedly connected or made integral.
  • Spacers 130, 132, 134 may be made of glass, concrete, plastic, insulation block, integral concrete over insulation block (such as the product known as LightguardTM, by T. Clear Corporation), or other material.
  • the spacing and dimensions of the spacers are predetermined to provide multiple functions, including temperature modulation resulting from heat exchange by fluid convection on the backside of modules 104, 106, 108, enabling pressure equalization between the top side and bottom side of modules 104, 106, 108, and enabling drainage of rainwater.
  • FIG. 1d shows an expanded view of spacer 112, 114 which is identical in construction to spacers 116, 118, 120, 122 and has a top adhesive layer 140, 142 for bonding or laminating modules 104, 106, 108 thereto in the field or in the shop.
  • any system can be used for attaching modules 104, 106, 108 to the spacers.
  • Spacer 114 which is identical to spacers 118, 122 preferably has a grooved profile 152
  • spacer 112 which is identical to spacers 116, 120 preferably has a tongued profile 154. In this way, interlocking joints are formed between adjacent integral assemblies for better resistance to wind uplift.
  • any means of integral locking is possible.
  • Modules 104, 106, 108, 110 are added to, bonded to, or otherwise attached to, respective spacers 112, 114, 116, 118, 120, 122, 124, 126, 130, 132, 134 in the manufacturing plant or in the field.
  • a roofing membrane is placed on a roof.
  • the modules and spacers are placed in arrays on top of the roof membrane.
  • roofing pavers are situated around the perimeter of photovoltaic module Such construction results in a simple, readily assembled roofing assembly which regulates the temperature of the photovoltaic module and roofing membrane.
  • a semi-continuous spatial layer is created below photovoltaic modules 104, 106, 108, 110 which enables the convection of a fluid, preferably air, through passageways created by the spacers.
  • the fluid convects within the passageways created by the spacers, transferring heat from the backside of the photovoltaic modules.
  • a fan or pump unit may be added to three convection of the fluid. Rainwater drains through the joints between the integral modules, onto and over the roofing membrane below.
  • the photovoltaic roofing assembly which can be used on a flat or mildly sloping roof, minimizes water leakage through the roof.
  • a pre-formed pedestal or spacer supports the photovoltaic module while facilitating temperature regulation through heat transfer to a convecting fluid.
  • the photovoltaic module provides multiple functions as a roofing component, including ballast, weather protection, and UV protection for the membrane layer below.
  • the assembly is lightweight relative to conventional roofing assemblies, relying on a combination of ballast weight and edge to edge connection to resist the forces of wind uplift.
  • Modules 104, 106, 108, 110 are interconnected, which prevents dislodging of individual modules, because each module is held in place by its adjoining modules.
  • the solar roofing modules are reusable. They can be readily disconnected and reassembled onto other roof tops.
  • the force of wind uplift at the interface between the module and paver portions of the assembly is reduced by introducing a spoiler of laminar air flow.
  • This spoiler may provide multiple functions as 1) edge to edge connection between module and paver portions of the assembly, and 2) raceway for electrical wiring.
  • FIGS. 2a-2c Tapered Profile with Convective Layer
  • FIGS. 2a-2c show sectional views of a second embodiment of the invention.
  • the assembly includes a plurality of photovoltaic modules 204, 206, 208, a plurality of pre-formed spacers, pedestals or supports 212, 214, 216 which are respectively disposed below modules 204, 206, 208 and integral therewith, or fixed thereto.
  • the spacers 212, 214, 216 are disposed on top of a roofing membrane 202.
  • Spacers 212, 214, 216 of the assembly can take several forms, including linear channels, point supports, or area supports.
  • FIG. 2b shows a sectional view of an embodiment of the assembly wherein spacers 224, 226 are disposed on top of membrane 202 and provide point support along the edges or corners for modules 204, 206, 208 to which they are fixedly connected or made integral. Spacers 224, 226 also ensure consistent spacing between modules 204, 206, 208 and enable water drainage.
  • FIG. 2c shows a sectional view of an alternate embodiment of the assembly wherein spacers 230, 232, 234 are disposed on top of membrane 202 and provide area support for modules 204, 206, 208 to which they are fixedly connected or made integral.
  • Spacers 230, 232, 234 may be made of glass, concrete, plastic, insulation block, or other material.
  • the distance between adjoining edges of the photovoltaic modules may be minimized, as the modules may ventilate by natural convective means on their back side.
  • Inclined photovoltaic modules 204, 206, 208 operate at a relatively high efficiency, due to their top surfaces being close to a plane normal to solar radiation.
  • the top planar surface of the array of modules presents a rough surface to wind currents flowing over the top of the modules, as opposed to a smooth surface when the modules are not inclined.
  • a rough surface serves to disrupt the laminar flow of wind, thereby reducing the forces of wind uplift.
  • This condition is true up to a limit on the height differential between the uppermost and lowermost edges of the photovoltaic modules. Beyond a certain height differential, the modules will "catch" the wind, and the design loses efficiency in terms of reducing the forces of wind uplift.
  • the allowable height differential is a complex function of the module weight, the nature of the edge to edge connection, the module size, and other factors. Wind tunnel testing is required to verify the relative height dimensions for each set of module conditions.
  • FIGS. 3a-3d Flat Profile with Phase Change Material
  • FIGS. 3a-3c show sectional views of a third embodiment of the invention.
  • the assembly includes a plurality of photovoltaic modules 304, 306, 308, a plurality of pre-formed containers or supports 312, 314, 316 which are respectively disposed below the plurality of modules 304, 306, 308 and integral therewith, or fixed thereto.
  • Containers 312, 314, 316 are disposed on top of a roofing membrane 302.
  • Containers 312, 314, 316 of the assembly may be made of open-cell foam, concrete, or other material into which a phase change material 350, 352, 354 has been imbibed or otherwise contained.
  • a phase change material is a material which absorbs a relatively high amount of heat energy per unit of weight in the process of changing phase from a solid to liquid at its melting point temperature, or from a liquid to gas at its boiling point temperature. The amount of heat absorbed in each case is commonly referred to as the material's heat of fusion and heat of vaporization, respectively.
  • FIG. 3b shows pre-formed assemblies 324, 326, 328 which are preferably metal in order to conduct heat more effectively and form pockets or channels to enable transfer of heat from phase change material 360, 362, 364, 366, 368 to a convecting fluid, preferably air.
  • FIG. 3c shows a sectional view of a commercially available aluminum sandwich honeycomb structure 340, 342, 344 which contains phase change material and which is bonded to the bottom side of modules 304, 306, 308 and supported on spacers 346, 348.
  • phase change material is preferably of the type known as linear crystalline alkyl hydrocarbons due to their low cost and melting temperatures in the range of 35-70 degrees centigrade.
  • phase change material By incorporating a phase change material with a predetermined melting point temperature, it is possible to specify precisely the maximum temperature experienced by the assembly and also by the building roof below. By doing so, the photovoltaic module efficiency is enhanced, and the building thermal efficiency is increased.
  • the container of the phase change material can also serve as spacer or support structure for the photovoltaic module, thus reducing material costs.
  • FIG. 3 The assembly of FIG. 3 is especially suited for thin-film photovoltaic materials which can benefit from lamination to a rigid substrate.
  • An example is the photovoltaic "bead” technology developed by Texas Instruments, Inc. which incorporates crystalline silicon beads onto a thin metal foil.
  • FIGS. 4a-4c Tapered Profile with Phase Change Material
  • FIGS. 4a-4c show sectional views of a fourth embodiment of the invention.
  • the assembly includes a plurality of photovoltaic modules 404, 406, 408, a plurality of pre-formed containers or supports 412, 414, 416, which are respectively disposed below the plurality of modules 404, 406, 408, and integral therewith, or fixed thereto.
  • Containers 412, 414, 416 are disposed on top of a roofing membrane 402.
  • Containers 412, 414, 416 of the assembly may be made of open-cell foam, concrete, metal or other material into which a phase change material 450, 452, 454 has been imbibed or otherwise contained.
  • phase change material 450, 452, 454 can take several forms.
  • FIG. 4b shows means of containment using pre-formed pockets or channels 424, 426, 428.
  • FIG. 4c shows a detail of a sectional view of a commercially available aluminum sandwich honeycomb structure 440, 442, 444 which contains phase change material and which is bonded to the bottom side of modules 406, 408 and supported on spacers 446, 448.
  • Inclined photovoltaic modules 404, 406, 408 operate at a relatively high efficiency, due to their top surfaces being close to a plane normal to solar radiation.
  • the top planar surface of the array of modules presents a rough surface to wind currents flowing over the top of the modules.
  • a rough surface of pre-determined dimensions can serve to disrupt laminar flow, thereby reducing the forces of wind uplift.
  • FIGS. 5a-5e Flat Profile with Insulation Block and Convective Layer
  • FIG. 5a shows a sectional view of a fifth embodiment of the invention.
  • the assembly includes a plurality of photovoltaic modules 504, 506, 508, 510, a plurality of pro-formed insulation blocks 512, 514, 516, 518 which are respectively disposed below the plurality of modules 504, 506, 508, 510 and integral therewith, or fixedly connected thereto.
  • Insulation blocks 512, 514, 516, 518 are disposed on top of a roofing membrane 502.
  • Insulation block 514 which is identical in construction to insulation blocks 512, 516, 518, preferably has a grooved profile 550 along one edge, and a tongued profile 552 along the opposite edge. In this way, interlocking joints are formed between adjacent assemblies for better resistance to wind uplift. However, any means of integral locking is possible.
  • modules 504, 506, 508 of the roofing assembly are connected to spacers, pedestals or supports 520, 522, 524, 526 which rest on insulation blocks 532, 534, 536 situated over roofing membrane 502.
  • Module 506, attached to spacers 522, 524 may span and be bonded to insulation blocks 532, 534 in order to provide a positive connection between adjacent insulation blocks 532, 534.
  • module 506 and module 508 may positively connect insulation blocks 534, 536 and 536, 538, respectively, forming an edge to edge integral assembly.
  • any means of positive connection between modules 504, 506, 508 is possible.
  • Spacers 520, 522, 524, 526 may be made of metal, insulation block, plastic, fiberglass, or other material and have pre-determined spacing and dimensions to provide multiple functions, including enabling heat exchange by fluid convection on the backside of modules 504, 506, 508; enabling pressure equalization between the topside and bottomside of modules 504, 506, 508; enabling insulation blocks 532, 534, 536 to ventilate and expire moisture, thus maintaining their insulation value and extending their life; and enabling drainage of rainwater.
  • FIG. 5c shows an expanded view of spacer 522, which is identical in construction to spacers 520, 524, 526 and has a top adhesive layer 560 for bonding or laminating module 506 thereto in the field or in the shop.
  • Spacer 522 has a bottom adhesive layer 562 for bonding or laminating insulation block 534 thereto in the field or in the shop.
  • any system can be used for attaching module 506 to spacer 522 and spacer 522 to insulation block 532.
  • Insulation blocks 512, 514, 516, 518 are bonded or otherwise attached on their top surface to modules 504, 506, 508, 510 either in the shop, thereby forming a shop-assembled, two-layer solar roofing module, or at the site of construction.
  • the solar roofing modules are laid in the field over roofing membrane 502.
  • roofing pavers are situated around the arrays of solar roofing modules. Electrical raceways are installed along those edges of the array of solar roofing modules, or the raceways are made integral to the solar roofing modules or roofing pavers.
  • a semi-continuous spatial layer created below modules 504, 506, 508, 510 enables the convection of a fluid, preferably air.
  • the fluid convects within the passageways created by the pre-formed insulation blocks or spacers, transferring heat from the backside of the photovoltaic modules.
  • a fan or pump unit may be added to force convection of the fluid.
  • Rainwater drains through the joints between the integral modules, onto and over the roofing membrane below.
  • the assembly provides added protection for the roofing membrane against degradation resulting from exposure to ultraviolet radiation, weather elements, and from high temperatures, thus extending the life of the membrane.
  • the assembly displaces the need for building insulation placed below the roofing membrane.
  • the assembly avoids the need for roof hold-downs and penetrations, thus reducing the cost and complexity of the installed system.
  • FIGS. 6a-6b Tapered Profile with Insulation Block and Convective Layer
  • FIGS. 6a-6b show sectional views of a sixth embodiment of the invention.
  • the assembly includes a plurality of photovoltaic modules 604, 606, 608, a plurality of insulation blocks 612, 614, 616 respectively disposed below the plurality of modules 604, 606, 608 and integral therewith, or fixed thereto.
  • Insulation blocks 612, 614, 616 are disposed on top of a roofing membrane 602 and have a tapered profile in order to orient modules 604, 606, 608 toward a direction of increased sun exposure.
  • Insulation block 614 which is identical in construction to insulation blocks 612, 616, preferably has a grooved profile 650 along one edge, and a tongued profile 652 along the opposite edge. In this way, interlocking joints are formed between adjacent assemblies for better resistance to wind uplift. However, any means of integral locking is possible.
  • FIG. 6b a variation of the assembly of FIG. 6a shows photovoltaic modules 604, 606, 608 connected to spacers, pedestals or supports 620, 622, 624 which rest on insulation blocks 632, 634, 636 situated over roofing membrane 602.
  • Inclined photovoltaic modules 604, 606, 608 operate at a relatively high efficiency, due to their top surfaces being close to a plane normal to solar radiation.
  • the top planar surface of the array of modules presents a rough surface to wind currents flowing over the top of the modules.
  • a rough surface serves to disrupt laminar flow, thereby reducing the forces of wind uplift.
  • FIGS. 7a-7c Flat Profile with Insulation Block and Phase Change Material
  • FIGS. 7a-7c show sectional views of a seventh embodiment of the invention.
  • the assembly includes a plurality of photovoltaic modules 704, 706, 708, 710, a plurality of pre-formed insulation blocks 712, 714, 716, 718 which are respectively disposed below the plurality of photovoltaic modules 704, 706, 708, 710 and integral therewith, or fixed thereto.
  • Insulation blocks 712, 714, 716, 718 are disposed on top of a roofing membrane 702.
  • Insulation blocks 712, 714, 716, 718 of the assembly contain a phase change material 750, 752, 754, 756.
  • the assembly shows insulation blocks 712, 714, 716, 718 as a means of containment of phase change material 750, 752, 754, 756, the means of containment can take several forms.
  • FIG. 7b shows pre-formed containers 724, 726, 728 which contain phase change material and which are formed to enable fluid convection for transferring heat away from the phase change material.
  • Channels 724, 726, 728 are preferably metal in order to conduct heat effectively.
  • FIG. 7c shows a sectional view of a commercially available aluminum sandwich honeycomb structure 760, 762, 764 which contains phase change material and which is bonded to the bottom side of modules 704, 706, 708 and supported on insulation block 776, 778, 780.
  • the photovoltaic modules, bonded to the honeycomb structure could rest on spacers over the roofing membrane.
  • the advantage of the assembly of FIG. 7 is that it combines the advantages of the assemblies of FIG. 3 and FIG. 5.
  • FIGS. 8a-8c Tapered Profile with Insulation Block and Phase Change Material
  • FIGS. 8a-8c show sectional views of an eighth embodiment of the invention.
  • the assembly includes a plurality of photovoltaic modules 804, 806, 808, a plurality of pre-formed insulation blocks 812, 814, 816 which are respectively disposed below the plurality of modules 804, 806, 808 and integral therewith, or fixed thereto.
  • Insulation blocks 812, 814, 816 are disposed on top of a roofing membrane 802 and have a tapered profile for orientation of their sloped surface in the direction of maximum sun exposure.
  • Insulation blocks 812, 814, 816 contain phase change material 850, 852, 854.
  • FIG. 8a shows insulation blocks 812, 814, 816 as a means of containment of phase change material 850, 852, 854, the means of containment of a phase change material can take several forms.
  • FIG. 8b shows pre-formed containers 824, 826, 828 which are shaped to contain phase change material 850, 852, 854 and to enable fluid convection for transferring heat.
  • Containers 824, 826, 828 are preferably metal in order to conduct heat effectively.
  • FIG. 7c shows a sectional view of a commercially available aluminum sandwich honeycomb structure 860, 862, 864 which contains phase change material and which is bonded to the bottom side of modules 804, 806, 808 and supported on insulation blocks 876, 878, 880.
  • the advantage of the assembly of FIG. 8 is that it combines the advantages of the assemblies of FIG. 4 and FIG. 5.
  • FIG. 9 Perspective View of the Photovoltaic Roofing Assembly
  • FIG. 9 shows a perspective view of the photovoltaic roofing assembly where solar roofing modules form an array 902 which is situated on a building rooftop.
  • roofing paver sections 904 are situated between predetermined areas of array 902 to provide walkways and perimeters around roof penetrations, such as vents, and around roof equipment, such as heating, ventilating, and air conditioning equipment.
  • the present invention provides a simple, efficient, quickly installed, reusable, and low-cost solar module assembly for roofs or other flat or mildly sloping surfaces.
  • the integral solar module unit consisting of a solar module bonded to insulation block can be utilized independent of a roofing membrane.
  • the solar roofing assembly may include an additional layer consisting of fabric or other material disposed above the roofing membrane and below the photovoltaic module with spacers, which layer may provide an additional protective barrier for the roofing membrane and/or slipsheet.
  • the solar modules with pedestals or spacers may include leveling plates placed under or over the pedestals or spacers for leveling the photovoltaic modules, or for achieving a pre-determined slope of the photovoltaic modules.
  • the insulation block may be coated with an intumescent coating or other means of fireproofing in order to achieve a desired fire rating as a building roofing assembly.
  • the edge-to-edge connection between adjacent modules was often shown as a tongue and groove assembly, any means of edge connection is possible, including mechanical clips, adhesives, "skewer” inserts which penetrate the insulation block, and other means.
  • the positive connection between modules may be accomplished as follows.
  • the photovoltaic modules may rest on spacers which in rum rest on insulation board which is loose laid on the roofing membrane.
  • the photovoltaic modules may then span and be bonded to adjacent insulation blocks which would provide a positive connection between adjacent insulation blocks and adjacent photovoltaic modules. The latter would assist the assembly in resisting the forces of wind uplift.
  • the insulation block may include a lining for containment of the phase change material.
  • the top of all insulation blocks may be painted with a paint which is opaque to ultraviolet radiation, thereby lengthening the life of the insulation block in applications where the photovoltaic module is not opaque to ultraviolet radiation.
  • the spacers need not be made integral with the photovoltaic module in the shop, but may be laid in the field as stringers and the PV modules attached thereto in the field.

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  • Engineering & Computer Science (AREA)
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  • General Engineering & Computer Science (AREA)
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  • Civil Engineering (AREA)
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  • Power Engineering (AREA)
  • Computer Hardware Design (AREA)
  • General Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Roof Covering Using Slabs Or Stiff Sheets (AREA)
  • Photovoltaic Devices (AREA)
US08/267,499 1994-06-29 1994-06-29 Thermally regulated photovoltaic roofing assembly Expired - Lifetime US5505788A (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
US08/267,499 US5505788A (en) 1994-06-29 1994-06-29 Thermally regulated photovoltaic roofing assembly
MX9606581A MX9606581A (es) 1994-06-29 1995-06-28 Conjunto de techado fotovoltaico, regulado termicamente.
CA002192838A CA2192838C (fr) 1994-06-29 1995-06-28 Ensemble de couverture photovoltaique a regulation thermique
EP95924767A EP0767859A4 (fr) 1994-06-29 1995-06-28 Ensemble de couverture photovoltaique a regulation thermique
AU29153/95A AU691635B2 (en) 1994-06-29 1995-06-28 Thermally regulated photovoltaic roofing assembly
JP50346796A JP3777454B2 (ja) 1994-06-29 1995-06-28 熱調節された光起電ルーフィング・アセンブリ
CN95193861A CN1082124C (zh) 1994-06-29 1995-06-28 安装在一个支承面上的光电池组件及其制造方法
PCT/US1995/008321 WO1996000827A1 (fr) 1994-06-29 1995-06-28 Ensemble de couverture photovoltaique a regulation thermique

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US08/267,499 US5505788A (en) 1994-06-29 1994-06-29 Thermally regulated photovoltaic roofing assembly

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US5505788A true US5505788A (en) 1996-04-09

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US (1) US5505788A (fr)
EP (1) EP0767859A4 (fr)
JP (1) JP3777454B2 (fr)
CN (1) CN1082124C (fr)
AU (1) AU691635B2 (fr)
CA (1) CA2192838C (fr)
MX (1) MX9606581A (fr)
WO (1) WO1996000827A1 (fr)

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EP0767859A1 (fr) 1997-04-16
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CA2192838C (fr) 2009-01-06
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MX9606581A (es) 1997-07-31
CA2192838A1 (fr) 1996-01-11
AU691635B2 (en) 1998-05-21
EP0767859A4 (fr) 1997-07-30
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JPH10502771A (ja) 1998-03-10
JP3777454B2 (ja) 2006-05-24

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